Heat transfer tube and method for producing same

ABSTRACT

A heat transfer tube includes: a tube body made of an extruded material of an aluminum alloy having a composition including: 0.3 mass % or more and less than 0.8 mass % of Mn; more than 0.1 mass % and less than 0.32 mass % of Si; 0.3 mass % or less of Fe; 0.06 mass % or more and 0.3 mass % or less of Ti; and Al balance including inevitable impurities, a ratio of a Mn content to a Si content, Mn %/Si %, exceeding 2.5; and a Zn-containing layer provided to an outer surface of the tube body.

CROSS-REFERENCE TO PRIOR APPLICATIONS

This application is a divisional of U.S. application Ser. No.14/387,990, filed Sep. 25, 2014 which is a National Stage ofPCT/JP2013/05859, filed Mar. 25, 2013 and claims the benefit of priorityon Japanese Patent Application No. 2012-072302, filed Mar. 27, 2012, theentire contents of which are incorporated herein by reference.

FIELD

The present invention relates to a heat transfer tube for a heatexchanger configured to have an excellent corrosion resistance and amethod of producing the heat transfer tube.

BACKGROUND

The heat exchanger made of an aluminum alloy includes a heat transfertube, fins, and header pipes as the major components, and ismanufactured by brazing. In the manufacturing process of the heatexchanger made of an aluminum alloy, the brazing sheet, on which anAl—Si alloy brazing material is cladded, has been utilized broadly.However, in recent years, products can be manufactured with low cost byapplying a brazing filler composition, which is made of a mixture of: anAl—Si alloy powder or a Si powder; a flux; and a binder, on the surfaceof a heat transfer tube (extruded heat transfer tube) made of anextruded material without using the blazing sheet.

However in the case of using the above-mentioned brazing fillercomposition, Si concentration increases on the surface of the heattransfer tube and decreases in the internal part of the tube since Sidiffuses from the surface of the extruded heat transfer tube to theinternal part due to heat during brazing, causing formation ofelectrical potential gradient, in which electrical potential is higheron the surface and lower in the internal part, in the heat transfertube. Due to the electrical potential gradient formed in the heattransfer tube, the heat transfer tube corrodes and formation of pittingcorrosion occurs, which causes the problems of refrigerant leakage ordecreased strength.

As a countermeasure of these problems, a structure with improvedcorrosion resistance has been proposed. In this structure, electricalpotential gradient, in which the electrical potential on the surface ofthe heat transfer tube is low and the electrical potential in theinternal part is high, is formed by forming a Zn-diffusing layer on thesurface of the heat transfer tube. The Zn-diffusing layer is formed byperforming mixed application of a Zn-containing flux on the surface ofthe heat transfer tube with Si powder and the like.

The inventors of the present invention have proposed a tube for a heatexchanger in Patent Literature 1 (PTL 1). In the tube, a brazingcoating, which includes Si powder whose application amount is 1-5 g/m²,and Zn-containing flux whose application amount 5-20 g/m², is thrilledon the outer surface of the extruded heat transfer tube, the outersurface being jointed to fins.

According to this proposal, the Si powder melts to be brazing liquidduring brazing since the Si powder and the Zn-containing flux are mixedin. Thus, Zn in the flux diffuses uniformly in the brazing liquid andspreads over the surface of the tube uniformly. Diffusion rate of Zn issignificantly higher in a liquid phase such as the brazing liquid thanthat in a solid phase. Thus, by having this configuration, Znconcentration can be kept uniform over the surface of the heat transfertube. Because of this, a uniform sacrificial anode layer can be formedon the surface of the extruded heat transfer tube, and corrosionresistance of the extruded heat transfer tube for a heat exchanger canbe improved.

RELATED ART DOCUMENTS Patent Literature

PTL 1: Japanese Unexamined Patent Application, First Publication No.2004-330233

SUMMARY Problems to be Solved by the Present Invention

However, based on the further studies by the inventors of the presentinvention, even if Zn concentration over the outer surface of theextruded heat transfer tube becomes uniform, selective corrosion occursat the extrusion weld part in a heat exchanger whose extrusion heattransfer tube is thin-walled. This causes a problem of reduced corrosionresistance.

Generally, the weld line in the extruding work means the line generatedby merging of two flows of softened metal in the mold when molding isperformed by putting metal softened by being heated into the mold. Thepart of this weld line is referred as the extrusion weld part.

The inventors of the present invention found that the component elementsof the aluminum alloy constituting the extruded heat transfer tube andthe like are need to be examined thoroughly in order to improvecorrosion resistance further in the extruded heat transfer tube, whichhas an extrusion weld part by being formed by extruding work and isbrazed in the presence of the Zn-diffusion explained above. Also theyfound that the method of producing the aluminum alloy itself effects onthe corrosion resistance and finally made the present invention.

The present invention is made under the circumstances described above.The purpose of the present invention is to provide: a heat transfer tubefor a heat exchanger whose main body is the extruded tube with excellentcorrosion resistance and extrudability, and a method of producing theheat transfer tube.

Means to Solving the Problems

An aspect of the present invention is a heat transfer tube including: atube body made of an extruded material of an aluminum alloy having acomposition including: 0.3 mass % or more and less than 0.8 mass % ofMn; more than 0.1 mass % and less than 0.32 mass % of Si; 0.3 mass % orless of Fe; 0.06 mass % or more and 0.3 mass % or less of Ti; and Albalance including inevitable impurities, a ratio of a Mn content to a Sicontent, Mn %/Si %, exceeding 2.5; and a Zn-containing layer provided toan outer surface of the tube body.

In the heat transfer tube, the Zn-containing flux layer may be: a Znlayer, a Zn-containing flux layer; or a layer including a mixture of aZn-containing flux, a brazing filler, and/or a binder.

In the heat transfer tube, the body of the tube may have a flat tubeshape with multiple holes including multiple passage of fluid.

In the heat transfer tube, the aluminum alloy may further include: 0.5mass % or less of Cu; less than 0.05 mass % of Mg; and less than 0.03mass % of Cr

In the heat transfer tube, 3000/mm² or less of intermetallic compoundprecipitates whose size is 1.0 μm or more in a circle equivalentdiameter may be precipitated in the heat transfer tube alter a brazingheat treatment or a Zn diffusing treatment of the heat transfer tube.

In the heat transfer tube, the aluminum alloy constituting the tube bodymay be an alloy of the aluminum alloy subjected to a homogenizationtreatment in which having a composition including: is kept at 450-650°C. for 2-24 hours.

In the heat transfer tube, a heating rate from a room temperature to450° C. may be 50-180° C./h; a heating rate from 450° C. to atemperature of the homogenization treatment may be 10-80° C./h; and acooling rate from the temperature of the homogenization treatment to200° C. may be 50-400° C./h, in the homogenization treatment.

In the heat transfer tube, a brazing heat treatment or a Zn diffusingtreatment may be performed on the heat transfer tube at 610° C. orlower.

In the heat transfer tube, a refrigerant flowing an inside of the heattransfer tube may be fluorocarbon.

Another aspect of the present invention is a method of producing a heattransfer tube with a tube body having a composition including: 0.3 mass% or more and less than 0.8 mass % of Mn; more than 0.1 mass % and lessthan 0.32 mass % of Si; 0.3 mass % or less of Fe; 0.06 mass % or moreand 0.3 mass % of less of Ti; and Al balance including inevitableimpurities, a ratio of a Mn content to a Si content, Mn %/Si %,exceeding 2.5; and a Zn-containing layer provided to an outer surface ofthe tube body, the method including the step of performing ahomogenization treatment in which an ingot of the aluminum alloy havingthe composition is kept at a temperature of 450-650° C. for 2-24 hoursafter being casted.

The method of producing the heat transfer tube may further include thesteps of: casting an aluminum alloy ingot from molten metal with theabove-explained composition; performing the homogenization treatment;producing a body of the tube by extruding the ingot after thehomogenization treatment; and providing a Zn-containing layer to theouter surface of the body of the tube.

In the method of producing the heat transfer tube, a heating rate from aroom temperature to 450° C. may be 50-180° C./h; a heating rate from450° C. to a temperature of the homogenization treatment may be 10-80°C./h; and a cooling rate from the temperature of the homogenizationtreatment to 200° C. may be 50-400° C./h, in the homogenizationtreatment.

Effects of the Invention

In the heat transfer tube, which is an aspect of the present invention,the body of the tube is constituted from the aluminum alloy extrudedmaterial including Mn, Si, Fe, and Ti in specific ranges, and the ratioof the Mn content to the Si content exceeds 2.5. Thus, when theZn-containing layer is provided to the outer surface of the body of thetube and the heat exchanger is constituted by performing brazing todiffuse Zn, the heat exchanger with excellent corrosion resistance canbe provided. Also, by the present invention, the heat transfer tubewhose body is the extruded tube with excellent extrudability can beprovided.

Also, in the heat transfer tube, which is an aspect of the presentinvention, the number of the intermetallic compound precipitates whosesize is 1.0 μm or more in a circle equivalent diameter precipitatedafter the brazing heat treatment or the Zn diffusing treatment islimited to 3000/mm² or less. Thus, the heat exchanger having the heattransfer tube with excellent corrosion resistance can be provided.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 A front view showing an example of a heat exchanger with the heattransfer tube related to the present invention.

FIG. 2 A partial enlarged cross-sectional view indicating an assembledstate in which header pipes, heat transfer tubes, and fins are assembledin the heat exchanger with the heat transfer tube related to the presentinvention.

FIG. 3 A partial enlarged cross-sectional view indicating a heatexchanger, in a state where header pipes, heat transfer tubes, and finsare assembled and brazed, in the heat exchanger with the heat transfertube related to the present invention.

FIG. 4 A drawing indicating an example of the cross-sectional shape ofthe heat transfer tube related to the present invention.

DESCRIPTION OF EMBODIMENTS

The present invention is explained in detail below based on theembodiments indicated in the attached drawings.

FIG. 1 is a front view showing an example of a heat exchanger with theheat transfer tube related to the present invention. The heat exchanger100 in the present embodiment is constituted mainly by: the header pipes1, 2 placed in parallel on the right and left spaced away each other;the heat transfer tubes 30 made of flat-shaped extruded tubes, which arespaced away with an interval and in parallel each other between theheader pipes 1, 2, and are jointed to the header pipes 1, 2substantially orthogonally and the fins 4 in a wave-shape brazed to eachof the heat transfer tube 30. The bodies of the header pipes 1, 2, theheat transfer tubes 30, and the fins 4 are constituted by aluminumalloys explained later.

More specifically, slits 6 shown in FIGS. 2 and 3 are formed on the sidesurfaces of the header pipes 1, 2 on their sides facing each other alongthe longitudinal direction of each of the header pipes 1, 2 with aconstant interval. The heat transfer tithes 30 are installed between theheader pipes 1, 2 by inserting the end parts of the heat transfer tubes30 in the slits 6 of the header pipes 1, 2 facing each other. The fins 4are placed on the front and rear surfaces of the heat transfer tubes 30installed between the header pipes 1, 2 with a predetermined interval.These fins 4 are brazed on the front surface or the rear surface of theheat transfer tubes 30. That is, as shown in FIG. 3, the fillets 8 areformed by the brazing filler at the parts in which the end parts of theheat transfer tubes 30 are inserted in the slits 6 of the header pipes1, 2, and the heat transfer tubes 30 are brazed on the header pipes 1,2. Also, the fillets 9 are formed by the brazing filler at the gap partsformed by facing: the peak parts of the wave shape of the fins 4; andthe closely contacting front surface or the rear surface of the heattransfer tubes 30, each other, and the fins 4 are brazed on the frontand the rear surfaces of the heat transfer tubes 30.

The heat exchanger 100 of the present embodiment is produced by brazingthe assembled body of the heal exchanger 101, which is configured asshown in FIG. 2 by assembling: the header pipes 1, 2; the heat transfertubes 30 installed between the header pipes 1, 2; and the fins 4, asexplained in the production method that explained later.

To the heat transfer tubes 30 before brazing, the brazing coatings(brazing filler coating) 7, which has a blending composition of 1-6 g/m²of Si powder and 2-20 g/m² of Zn-containing fluoride compound-basedflux, are formed on the front and the rear surfaces on which the fins 4are jointed in such a way that the coating covers the large portions ofthe front and the rear surfaces of the tube body (extruded tube) 3 asshown FIG. 4. As the Zn-containing fluoride compound-based flux, about2-20 g/m² of KZnF₃ may be blended, or a flux blended with 2-20 g/m² of amixture of KZnF₃, K₃AlF, and KAlF₄ may be used.

The brazing coatings 7 with the above-described composition may includeabout 0.5-3.5 g/m² of binder (such as the acryl-based resin) in additionto the Si powder and the flux.

The heat transfer tube 30 (tube body 3) in the present embodiment is anextruded tube (extrude heat transfer tube) formed by performingextruding work on an aluminum alloy. In the tube body 3, passages 3C areformed inside as shown in FIG. 4. The tube body 3 also has flat frontsurface (upper surface) 3A and the rear surface (lower surface) 3B, andthe side surface 3D adjacent to the front surface 3A and the rearsurface 3B. The tube body 3 is configured to be the flat tube withmultiple holes shown in the cross section shown in FIG. 4. In theexample shown in FIG. 4, there are 10 of the passages 3C formed in thetube body 3. However, the number of the passage per a tube can be chosenarbitrarily. Generally, several to several dozens of passages are formedper a tube. In an actual condition, the tube body 3 has a dimension of 1mm-several mm of height (total thickness) and about several dozen mm ofwidth (10-40 mm for example) as the extruded heat transfer tube. Thethickness of the wall part sectioning the passages 3C has a thinstructure of about 0.1-1.5 mm.

In the case where the tube body 3 with the cross-sectional shape shownin FIG. 4 is utilized and the tube body 3 is formed from the aluminumalloy with the composition explained later, the sacrificial anode layer3 a including Si and Zn is formed as shown in FIG. 3 as a result ofdiffusion of Si and Zn included in the brazing coating 7 on the frontsurface part and the rear surface part of the tube body 3 after brazingat the brazing temperature.

The composition constituting the brazing coating 7 is explained below.As the brazing coating 7, the mixture of the Si powder and the fluxexplained below or the mixture of the Si powder, the flux, and thebinder explained below can be used.

The Si powder reacts with Al constituting the tube body 3 to form thebrazing filler joining fins 4 and the heat transfer tubes 30. In thisease, the Zn-containing flux and the Si powder are melted to be thebrazing liquid during brazing. Zn in the flux is uniformly diffused inthe brazing liquid to be spread uniformly on the surface of the tubebody 3. The diffusion rate of Zn in the brazing liquid, which is inliquid phase, is significantly higher than that in solid phase. Becauseof this, Zn diffuses uniformly and the Zn concentration becomessubstantially uniform on the surface of the heat transfer tube 30 in theplane direction.

The Zn-containing fluoride compound-based flux has an effect to form thesacrificial anode layer 3 a, in which Zn that adjusts the electricalpotential of the sacrificial anode layer to a lower potential properlyis diffused, on the surface of the heat transfer tube 30 during brazing.Also, it has an effect to remove oxides on the surface of the tube 3during brazing, improving the brazability by stimulating spreadingproperty and wettability of the brazing filler.

As the Zn-containing fluoride compound-based flux, KZnF₃, a mixture ofKZnF₃, K₃AlF, KAlF₄, or the like may be used.

The coating material may include binder in addition to the Si powder andthe Zn-containing fluoride compound-based flux. As a suitable example ofthe binder, the acryl-based resin can be named.

The method for applying composition made of the Si powder, the flux, andthe binder is not particularly limited in the present invention. Thus,application can be performed by an at appropriate method, such as thespray method, the shower method, the flow coater method, the roll coatermethod, the brushing method, the dipping method, the electrostaticcoating method, and the like.

Also, the application area of the braying composition may be the entirefront surface or the entire rear surface of the tube body 3.Alternatively, it may a part of the front surface or the rear surface ofthe tube body 3. In short, it is acceptable if the brazing compositionis applied on the front surface area or the rear surface area of thetube body necessary for brazing the fins 4 at least.

The tube body 3 is wide of the aluminum alloy having a compositionincluding: 0.3 mass % or more and less than 0.8 mass % of Mn; more than0.1 mass % and less than 0.32 mass % of Si; 0.3 mass % or less of Fe;0.06 mass % or more and 0.3 mass % or less of Ti; and Al balance eludinginevitable impurities, a ratio of a Mn content to a Si content (Mn %/Si%) exceeding 2.5. The aluminum alloy may further include: 0.05 mass % orless of Cu; less than 0.05 mass % of Mg; and less than 0.03 mass % ofCr.

Reasoning for the limitations for each of the constituent elements ofthe tube body 3 is explained below.

{Si: More than 0.1 Mass % and Less than 0.32 Mass %}

The Si content is an important parameter for securing strength whilesecuring corrosion resistance. When the Si content is 0.1 mass % orless, the strength becomes insufficient. When it is included at 0.32mass % or more, extrudability of the alloy reduces due to occurrence ofpickups during extruding work. Thus, the number of the intermetalliccompound grain increases. Because of these, the Si content is set tomore than 0.1 mass % and less than 0.32 mass %.

{Mn: 0.3 Mass % or More and Less than 0.8 Mass %}

Mn is an effective element in forming the intermetallic compound with Siand the uniform sacrificial anode layer. Also, Mn improves corrosionresistance of the tube body 3 and its mechanical strength. It is aneffective element for improving extrudability during extrusion.

When the Mn content is less than 0.3 mass %, its strength becomesinsufficient and corrosion resistance decreases too. When the tube body3 includes 0.8 mass % or more of Mn, extrudability decreases due tooccurrence of pickups. Thus, the Mn content is set to 0.3 mass % or moreand less than 0.8 mass %.

{Fe: 0.3 Mass % or Less}

Fe is effective to secure corrosion resistance since Fe forms theintermetallic compound with Si and generates the uniform sacrificialanode layer. When the Fe content exceeds 0.3 mass %, corrosion rate(corrosion amount) increases and corrosion resistance decreases. Also,the number of the intermetallic compound grain increases. Thus, the Fecontent is set to 0.3 mass % or less.

{Ti: 0.06 Mass % or More and 0.3 Mass % or Less}

Ti improves corrosion resistance and contributes to improvement ofstrength of the tube body 3 too. When the Ti content is less than 0.06mass %, strength becomes insufficient and corrosion resistance reduces.When the Ti content is exceeds 0.3 mass %, the extrusion pressure of thealuminum alloy constituting the heat transfer tube increases, andextrudability decreases. Because of this, it becomes easier for theselective corrosion of the extrusion weld part to occur, reducingcorrosion resistance. Thus, the Ti content is set to 0.06 mass % or moreand 0.3 mass % or less.

{Cu: 0.05 Mass % or Less}

Cu suppresses corrosion rate and effective for improving corrosionresistance. However, when it exceeds 0.05 mass %, corrosion rate(corrosion amount) increases, grain boundary corrosion or selectivecorrosion of the extrusion weld part occurs, and corrosion resistancereduces. Thus, the Cu content is set to 0.05 mass % or less.

{Mg: 0.05 Mass % or Less}

Mg is effective for improving corrosion resistance. However, when itexceeds 0.05 mass %, selective corrosion of the extrusion weld partoccurs due to reduced extrudability, and corrosion resistance reduces.Thus, the Mg content is set to 0.05 mass % or less.

{Cr: Less than 0.03 Mass %}

Cr is effective for improving corrosion resistance. However, when itexceeds 0.03 mass %, selective corrosion of the extrusion weld partoccurs due to reduced extrudability, and corrosion resistance reduces.Thus, the Cr content is set to 0.05 mass % or less.

{Ratio of a Mn Content of a Si Content}

In the aluminum alloy for constituting the tube body 3 of the heattransfer tube of the present invention, it is preferable that the ratioof the Mn content to the Si content (Mn %/Si %) exceeds 2.5. When theratio of the Mn content to the Si content is 2.5 or less, corrosionresistance reduces.

The heat transfer tube 30 of the present invention may be configured insuch a way that 3000/mm² or less of intermetallic compound precipitateswhose size is 1.0 μm or more in a circle equivalent diameter areprecipitated after a brazing heat treatment or a Zn diffusing treatment.The precipitation amount (surface density) of the above-explainedintermetallic compound can be measured as the precipitation amount onthe surface of the flat part of the heat transfer tube 30 after thebrazing heat treatment or the Zn diffusing treatment. The measurementcan be performed by the particle analysis with an electron probemicro-analyzer (EPMA), for example.

The method for producing the above-explained heat transfer tube 30 isexplained below.

It is preferable that the aluminum alloy constituting the tube body 3 isprepared by: obtaining an ingot from the molten metal of the aluminumalloy with the specified composition; and performing the homogenizationtreatment in which the ingot is held at 450-650° C. for 2-24 hours.

By performing the homogenization treatment, coarse precipitates aredissolved. The homogenization treatment has an effect of allowing thedissolved coarse precipitates to be dissolved in the matrix again.

It is preferable that a heating rate from a room temperature to 450° C.is 50-180° C./h; a heating rate from 450° C. to a temperature of thehomogenization treatment is 10-80° C./h; and a cooling rate from thetemperature of the homogenization treatment to 200° C. is 50-400° C./h,in the homogenization treatment.

Setting the heating rate ranges as described above has an effect toimprove extrudability and corrosion resistance of the aluminum alloy.

Setting the cooling rate ranges as described above has an effect toimprove extrudability of the aluminum alloy.

The tube body 3 can be obtained by configuring the aluminum alloy, whichis treated by the above-explained homogenization treatment, in theextruded tube with multiple holes having the cross-sectional shape, forexample, indicated in FIG. 4 by the direct or indirect extrusion work.As an example of the tube body 3 produced in the present embodiment, theextruded tube with multiple holes having: width of 22 mm; height(thickness) of 1.2 mm; and 29 holes, can be mentioned. To satisfy thespecification, the thickness of the boundary wall dividing the hole ofthe tube body 3 is about 0.2 mm. Also, the weld lines are formed in thecenter of the R-portion (arc portion on the side surface) of the tubebody 3 and the central part in the height direction of the boundary walldividing the hole (central part of the tube body 3 in the thicknessdirection).

Next, the fins 4 are explained.

For the fins 4 which are jointed to the heat transfer tube 30, the alloymainly composed of the JIS3003 system aluminum alloy can be used, forexample. Alternatively, the fins 4 that may be formed from the aluminumalloy in which about 2 mass % of Zn is added to the JIS3003 systemaluminum alloy.

Fins 4 are machined into a wave shape through a hot-rolling process, acold-rolling process, and the like after melting the aluminum alloy withthe composition described above by a conventional method. The method forproducing the fins 4 is not particularly limited in the presentinvention and any known production method can be appropriately applied.In the case where the brazing filler is not provided to the side of theheat transfer tube 30, clad fins, on which a brazing filler layer isclad-pressure-bonded, may be used. In this case, a Zn layer may beprovided on the outer surface of the tube body 3 by a process such asthermal spraying of metallic zinc instead of the above-mentioned brazingcoating 7. Alternatively, the Zn-containing fluoride compound-based fluxor the mixture of the Zn-containing fluoride compound-based flux and thebinder may be applied. As the method for applying, the same methodsapplied in the application method of the brazing compound may be used.

Next, the header pipe 1 is explained.

As shown in FIGS. 2 and 3 as an example, the header pipe 1 is made ofthe three-layered structure, which is made of: the core layer 11; thesacrificial material layer 12 provided on the outer circumference sideof the core material; and the brazing filler layer 13 provided on theinner circumference side of the core material.

By providing the sacrificial material layer 12 on the outercircumference side of the core material layer 12, corrosion protectioneffect by the header pipe 1 can be obtained in addition to the corrosionprotection effect by the fins 4. Thus, sacrificial corrosion protectioneffect of the tube 3 in the vicinity of the header pipe 1 can be furtherimproved.

It is preferable that the core material layer 11 is made of an alloybased on Al—Mn-based alloy.

The sacrificial material layer 12 provided on the outer circumferenceside of the core material layer 11 is constituted from the aluminumalloy made of: 0.60-1.20 mass % of Zn; and the Al balance and inevitableimpurities. The sacrificial material layer 12 is unified to the corematerial layer 11 by clad rolling.

Next, the method of producing the heat exchanger 100, which is mainlyconstituted by the above explained header pipes 1, 2, the heat transfertubes 30, and fins 4, is explained.

FIG. 2 is a partial enlarged cross-sectional view of the heat exchangerassembled body 101 indicating an assembled state in which header pipes1, 2, heat transfer tubes 30, and fins 4 are assembled using the heattransfer tube 30 in which the brazing coating is applied on the tubebody 3 on the joining surface with the fins 4. FIG. 2 shows the stateprior to performing the heating brazing. In the heat exchanger assembledbody 101 shown in FIG. 2, the end part of the heat transfer tube 30 isinserted in and attached to the slit 6 provided to the header pipe 1.

When the heat exchanger assemble body 101, which is made of: the headerpipes 1, 2; the heat transfer tubs 30; and the fins 4 assembled as shownFIG. 2, is heated to the temperature higher than the melting point ofthe blazing filler and cooled down after heating, the brazing coating 7and the brazing filler layer 13 are melted each or the header pipe 1;the heat transfer tube 30; and the fin 4, is jointed as shown in FIG. 3.In this way, the heat exchanger 100 with the structure shown in FIGS. 1and 3 is obtained. At this time, the brazing filler layer 13 on theinner circumference side of the header pipe 1 is melted and flows in thevicinity of the slit 6 and forms the fillet 8 for the header pipe 1 andthe heat transfer tube 30 to be jointed.

Also, the brazing coating 7 on the front and the rear surfaces of theheat transfer tube 30 is melted and flows in the vicinity of the fins 4due to the capillary force and forms the fillet 9 for the heat transfertube 30 and the fin 4 to be jointed.

In brazing, the brazing coating 7 and the brazing filler layer aremelted by heating at an appropriate temperature under an appropriateatmosphere such as an inert atmosphere. Because of this, the activity ofthe flux is increased; Zn in the flux is precipitated on the surface ofthe material to be brazed (tube body 3) and diffuses in the thicknessdirection thereof. In addition, it destroys the oxide film on thesurfaces of the brazing filler and the material to be brazed; andstimulates wettability between the brazing filler and the material to bebrazed.

The heating temperature for brazing is the temperature higher than themelting point of the brazing filler as explained above. When it is thebrazing filler with the composition explained above, it can be heated inthe range of 580-610° C. After retaining it for 1-10 minutes, it can becooled down.

In brazing, a part of the matrix of the aluminum alloy constituting theheat transfer tube 30 and the tube body 3; and the composition of thebrazing coating 7 applied to the tube body 3, are reacted to be thebrazing filler material, and the heat transfer tubes 30 and the fins 4are brazed. By performing brazing, Zn in the flux diffuses on thesurface of the heat transfer tube 30.

According to the structure in the present embodiment, excellent brazingwithout residual Si powder can be obtained in brazing. Also, the fillet9 with a sufficient volume is formed between the heat transfer tubes 30and the fins 4. Also, the above-described sacrificial anode layer 3 a isformed.

The heat transfer tube 30 for the heat exchanger produced as explainedabove is constituted from the extruded material of the aluminum alloy,in which the tube body includes Mn, Si, Fe, and Ti in the specificcontent ranges and the ratio of the Mn content to the Si content exceeds2.5. Thus, in the case where the heat exchanger is configured byproviding the Zn layer or the Zn-containing layer on the outer surfaceside; and performing Zn diffusion by brazing, the heat exchanger withexcellent corrosion resistance can be provided.

Also, when the body is the heat transfer tube 30 made of the aluminumalloy with the above-described composition, the tube body 3 withexcellent extrudability can be obtained.

Next, the number of the intermetallic compound precipitates whose sizeis 1.0 μm or more in a circle equivalent diameter is set to 3000/mm² orless after the brazing heat treatment or the Zn diffusing treatment inthe heat exchanger formed by brazing using the heat transfer tubes 30.

By limiting the number of the intermetallic compound to 3000/mm² orless, corrosion resistance can be improved.

As explained above, by using the heat transfer tube 30, which has thebody made of extruded material of the aluminum alloy with thecomposition described above, the heat exchanger 100 with excellentcorrosion resistance can be provided.

EXAMPLE

After performing the homogenization treatment to the aluminum alloyingot with the compositions indicated in Table 1, extrusion work wasperformed to produce the flat tubes with 29 holes with a dimension of:22 mm of width, 1.2 mm of height (thickness).

When the homogenization treatment was performed to the aluminum alloyingots, the heating rate between the room temperature and 450° C. wasadjusted; the heating rate between 450° C. and the homogenizationtreatment temperature was adjusted; the homogenization temperature andtime were adjusted; and the cooling rate between the homogenizationtreatment temperature and 200° C. was adjusted, as shown in Table 2. Thetest samples were obtained by producing the flat extruded tubes by usingthe aluminum alloys obtained in each condition.

Next, Zn thermal spray was performed on the front and rear surfaces ofthe flat tubes except for Examples 3, 4, and 5.

In Example 3, the KZnF₃ powder (D(50) granularity 2.0 μm: 10 g/m²) wasapplied on the front and rear surfaces of the flat extruded tube.

In Examples 4 and 5, the brazing filler compositions were applied on thefront and rear surfaces of the flat extruded tube.

For the brazing Idler composition in Example 4, the mixture A that is amixture of: the Si powder (D(50) granularity 4 μm: 3 g/m²); and theKZnF₃ powder (D(50) granularity 2.0 μm: 10 g/m²) was used.

For the blazing filler composition in Example 5, the mixture B that is amixture of: the Si powder (D(50) granularity 4 μm: 3 g/m²); the KZnF₃powder (D(50) granularity 2.0 μm: 10 g/m²); and NOCOLOK flux (trademarkof Alcan Inc.) (K₃AlF₃+KAlF₄: 10 g/m²).

The test samples of the heat transfer tubes formed by applying theZn-containing layers on the flat extruded tubes as explained above wereaccommodated in the furnace under a nitrogen atmosphere, and heatingtreatment was performed at the temperature shown in Table 2 for 3minutes. By the heat treatment, the sacrificial anode layers were formedon the surfaces of the heat transfer tubes.

On the heat transfer tubes after the heat treatment, the corrosionresistance test of SWAAT-20 days was performed.

The composition of the aluminum alloy; the type of the Zn-containinglayer on the surface (indicated as “Types of surface Zn layer” in Table2); the number of intermetallic compounds on the surface of the heattransfer tube after the heat treatment corresponding to brazing (#/mm²);the condition of the homogenization treatment; the heating purpose; theheating temperature; and evaluations of the corrosion resistance and theextrudability, are indicated in Tables 1 and 2.

The corrosion resistance was evaluated based on the depth of the maximumcorrosion (μm).

The evaluation of the extrudability was the evaluation of: the extrusionpressure; the extrusion rate; and the condition of the surface of thefrat extruded tube. The evaluated product that could not be extruded dueto a too high extrusion pressure and the evaluated product with a largenumber of surface defects such as pickups or the like were graded as thegrade D (graded as a defective product). Evaluated products with almostno surface defect were graded based on the values of the extrusionpressure and the extrusion rate (the extrusion pressure being lower thanthe intended extrusion rate means the extrudability is better) andindicated by other grades as explained below. They were compared withthe aluminum alloys 3102 and 3003. It was graded as the grade A product,if the extrudability is equivalent or better than that of 3102 alloy. Itwas graded as the grade B product, if the extrudability was inferior to3102 alloy but superior to 3003 alloy. It was graded as the grade Cproduct, if the extrudability was equivalent to 3003 alloy.

TABLE 1 Number of intermetallic compounds Types whose sizes of are 1.0μm Mn Si Fe Ti Cu Mg Cr surface or more (mass %) (mass %) (mass %) (mass%) (mass %) (mass %) (mass %) Mn/Si Zn layer (#/mm²) Ex. 1 0.3 0.11 0.20.1 2.7 Thermal 1600 spraying Ex. 2 0.3 0.11 0.2 0.1 2.7 Thermal 1600spraying Ex. 3 0.3 0.11 0.2 0.1 2.7 KZnF₃ 1600 Ex. 4 0.3 0.11 0.2 0.12.7 Mixed 1600 layer A Ex. 5 0.3 0.11 0.2 0.1 2.7 Mixture B 1600 Ex. 60.7 0.2 0.2 0.1 3.5 Thermal 1800 spraying Ex. 7 0.6 0.11 0.2 0.1 5.5Thermal 1700 spraying Ex. 8 0.79 0.31 0.2 0.1 2.55 Thermal 1900 sprayingEx. 9 0.6 0.2 0.05 0.1 3 Thermal 1500 spraying Ex. 0.6 0.2 0.3 0.1 3Thermal 2500 10 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal 1800 11 sprayingEx. 0.6 0.2 0.2 0.1 3 Thermal 1650 12 spraying Ex. 0.6 0.2 0.2 0.1 3Thermal 2200 13 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal 1650 14 sprayingEx. 0.6 0.2 0.2 0.1 3 Thermal 2200 15 spraying Ex. 0.6 0.2 0.2 0.1 3Thermal 1700 16 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal 2100 17 sprayingEx. 0.6 0.2 0.2 0.06 3 Thermal 1800 18 spraying Ex. 0.6 0.2 0.2 0.3 3Thermal 1800 19 spraying Ex. 0.6 0.2 0.2 0.1 0.05 3 Thermal 1800 20spraying Ex. 0.6 0.2 0.2 0.1 0.04 3 Thermal 1800 21 spraying Ex. 0.6 0.20.2 0.1 0.02 3 Thermal 1800 22 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal2200 23 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal 2000 24 spraying Ex. 0.60.2 0.2 0.1 3 Thermal 1900 25 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal1500 26 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal 2800 27 spraying Ex. 0.60.2 0.2 0.1 3 Thermal 2000 28 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal1800 29 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal 1500 30 spraying Ex. 0.60.2 0.2 0.1 3 Thermal 1650 31 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal2700 32 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal 1650 33 spraying Ex. 0.60.2 0.2 0.1 3 Thermal 2700 34 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal1600 35 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal 2700 36 spraying Ex. 0.60.2 0.2 0.1 3 Thermal 2800 37 spraying Ex. 0.6 0.2 0.2 0.1 3 Thermal2600 38 spraying C. 0.1 0.2 0.2 0.1 0.5 Thermal 1600 Ex. 1 spraying C.0.4 0.2 0.2 0.1 2 Thermal 1700 Ex. 2 spraying C. 1 0.2 0.2 0.1 5 Thermal1900 Ex. 3 spraying C. 0.6 0.05 0.2 0.1 12 Thermal 1500 Ex. 4 sprayingC. 0.6 0.5 0.2 0.1 1.2 Thermal 3500 Ex. 5 spraying C. 0.6 0.2 0.5 0.1 3Thermal 4000 Ex. 6 spraying C. 0.6 0.2 0.2 0.03 3 Thermal 1800 Ex. 7spraying C. 0.6 0.2 0.2 0.4 3 Thermal 1800 Ex. 8 spraying C. 0.6 0.2 0.20.1 0.1 3 Thermal 1800 Ex. 9 spraying C. 0.6 0.2 0.2 0.1 0.1 3 Thermal1800 Ex. spraying 10 C. 0.6 0.2 0.2 0.1 0.2 3 Thermal 1800 Ex. spraying11

TABLE 2 Cooling rate Homo- Heating rate (° C./h) (° C./h) genizationRoom 450° C. to Homogenization Heating Corrosion temperature temperaturehomogenization temperature to Homogenization Heating temperatureresistance (° C.) to 450° C. temperature 200° C. time (h) purpose (° C.)(μm) extrudability Ex. 1 600 100 40 200 12 Zn-diffusing 600 80 Atreatment Ex. 2 600 100 40 200 12 Zn-diffusing 400 80 A treatment Ex. 3600 100 40 200 12 Brazing 600 80 A Ex. 4 600 100 40 200 12 Brazing 60080 A Ex. 5 600 100 40 200 12 Brazing 600 80 A Ex. 6 600 100 40 200 12Brazing 600 70 B Ex. 7 600 100 40 200 12 Brazing 600 65 B Ex. 8 600 10040 200 12 Brazing 600 75 B Ex. 9 600 100 40 200 12 Brazing 600 50 B Ex.600 100 40 200 12 Brazing 600 100 A 10 Ex. 600 100 40 200 12 Brazing 60070 B 11 Ex. 600 50 10 200 12 Brazing 600 70 B 12 Ex. 600 50 80 200 12Brazing 600 90 B 13 Ex. 600 180 10 200 12 Brazing 600 70 B 14 Ex. 600180 80 200 12 Brazing 600 90 B 15 Ex. 600 100 40 50 12 Brazing 600 70 B16 Ex. 600 100 40 400 12 Brazing 600 90 B 17 Ex. 600 100 40 200 12Brazing 600 75 B 18 Ex. 600 100 40 200 12 Brazing 600 65 B 19 Ex. 600100 40 200 12 Brazing 600 75 B 20 Ex. 600 100 40 200 12 Brazing 600 70 B21 Ex. 600 100 40 200 12 Brazing 600 70 B 22 Ex. 600 100 40 200 4Brazing 600 90 A 23 Ex. 600 100 40 200 8 Brazing 600 80 A 24 Ex. 600 10040 200 16 Brazing 600 75 B 25 Ex. 600 100 40 200 20 Brazing 600 65 B 26Ex. 450 100 40 200 2 Brazing 600 95 A 27 Ex. 450 100 40 200 24 Brazing600 75 B 28 Ex. 650 100 40 200 2 Brazing 600 80 B 29 Ex. 650 100 40 20024 Brazing 600 65 B 30 Ex. 600 40 5 200 12 Brazing 600 70 C 31 Ex. 60040 100 200 12 Brazing 600 150 B 32 Ex. 600 190 5 200 12 Brazing 600 70 C33 Ex. 600 190 100 200 12 Brazing 600 150 B 34 Ex. 600 100 40 20 12Brazing 600 70 C 35 Ex. 600 100 40 500 12 Brazing 600 140 B 36 Ex. 430100 40 200 2 Brazing 600 120 C 37 Ex. 430 100 40 200 12 Brazing 600 150C 38 C. 600 100 40 200 12 Brazing 600 270 A Ex. 1 C. 600 100 40 200 12Brazing 600 170 A Ex. 2 C. 600 100 40 200 12 Brazing 600 50 D Ex. 3 C.600 100 40 200 12 Brazing 600 70 D Ex. 4 C. 600 100 40 200 12 Brazing600 320 D Ex. 5 C. 600 100 40 200 12 Brazing 600 370 A Ex. 6 C. 600 10040 200 12 Brazing 600 160 B Ex. 7 C. 600 100 40 200 12 Brazing 600 70 DEx. 8 C. 600 100 40 200 12 Brazing 600 250 D Ex. 9 C. 600 100 40 200 12Brazing 600 170 D Ex. 10 C. 600 100 40 200 12 Brazing 600 170 D Ex. 11

The test samples of Comparative Examples 1 and 2 (C. Ex 1 and C. Ex 2)indicated in Tables 1 and 2 were test samples in which the ratios of theMn content to the Si content (Mn %/Si %) were 0.5 and 2, respectively.In the test samples of Comparative Examples 1 and 2, corrosionresistance was reduced since their ratios of the Mn content to the Sicontent were lower than 2.5.

The test sample of Comparative Examples 3 (C. Ex 3) indicated in Tables1 and 2 was the test sample including an excessive amount of Mn. In thetest sample of Comparative Example 3 (C. Ex 3), extrudability wasreduced. The test sample of Comparative Example 4 (C. Ex 4) was the testsample including an insufficient amount of Si. In the test sample ofComparative Example 4, extrudability was reduced.

The test samples of Comparative Example 5 (C. Ex 5) indicated in Tables1 and 2 was the test sample in which an excessive amount of Si wasincluded and the ratio of the Mn content to the Si content was 1.2. Inthe test sample of Comparative Example 5, corrosion resistance wasreduced and there was a problem on extrudability.

The test samples of Comparative Example 6 (C. Ex 6) indicated in Tables1 and 2 was the test sample including an excessive amount of Fe. In thetest sample of Comparative Example 6, corrosion resistance was reduced.The test samples of Comparative Example 7 (C. Ex 7) indicated in Tables1 and 2 was the test sample including an insufficient amount of Ti. Inthe test sample of Comparative Example 7, corrosion resistance wasreduced. In the test sample of Comparative Example 8 (C. Ex 8), whichwas the test sample including an excessive amount of Ti, extrudabilitywas reduced.

In the test sample of Comparative Example 9 (C. Ex 9) in Tables 1 and 2,there were problems of the deteriorated corrosion rate and occurrence ofgrain boundary corrosion due to excessive addition of Cu.

In the test sample of Comparative Examples 10 and 11 (C. Ex 10 and C. Ex11) indicted in Tables 1 and 2, since both of Mg and Cr increasedeformation resistance during extrusion, the selective corrosion problemin the weld part occurred because of increased extrusion pressure by theexcessive addition of these elements. In the case where the added,elements were segregated in the weld part in the extruded heat transfertube, the selective corrosion occurred in the shape tracing the weldline.

Contrary to the above-explained test samples of Comparative Examples,each test sample in Examples 1-38 (Ex 1-Ex 38) had excellent corrosionresistance and there was no problem on extrudability.

However, in the test samples of Examples 31-34 (Ex 31 and Ex 34), therewas a slight problem on extrudability on the aspect of the extrusionpressure and corrosion resistance was a bit reduced. The test samples ofExamples 31-34 were the test samples, in which the heating rate from theroom temperature to 450° C. was set to 40° C./h or 190° C/h; or the testsamples, in which the heating rate from 450° C. to the homogenizationtreatment temperature was set to 5° C./h or 100° C./h in thehomogenization treatment.

The test samples of Examples 35 and 36 (Ex 35 and Ex 36) were the testsamples in which the cooling rate from the homogenization treatmenttemperature to 200° C. was set to 20° C./h or 500° C./h. In the samplesof Examples 35 and 36, there was a slight problem on extrudability onthe aspect of the extrusion pressure; and corrosion resistance was a bitreduced.

Based on the above-described observation, it was interpreted thatpreferentially, the heating rate from room temperature to 450° C. wasset to 50-180° C./h; and the heating rate from 450° C. to thehomogenization treatment temperature was set to 10-80° C./h in thehomogenization treatment. Also, it is interpreted that the cooling ratefrom the homogenization treatment temperature to 200° C. was set to50-400° C./h.

The test samples of Examples 37 and 38 (Ex 37 and Ex 38) were thesamples in which the temperature of the homogenization treatment was setto 430° C. In Examples 37 and 38, corrosion resistance was a bit reducedand there was a slight problem in extrudability based on the conditionon the surfaces of the flat extruded tubes. Because of this, it wasinterpreted that the performing the homogenization treatment at 450° C.or higher was preferable.

INDUSTRIAL APPLICABILITY

According to the present invention, an extruded tube with excellentcorrosion resistance, in which selective corrosion at the extrusion weldpart is suppressed, can be provided. In addition, by using the heattransfer tube whose body is this extruded tube, a heat exchanger withexcellent corrosion resistance can be provided.

1. (canceled) 2: An extruded heat transfer tube with internal passages,the heat transfer tube comprising: a tube body made of an extrudedmaterial of an aluminum alloy having a composition including: 0.3 mass %or more and less than 0.8 mass % of Mn; more than 0.1 mass % and lessthan 0.32 mass % of Si; 0.3 mass % or less of Fe; 0.06 mass % or moreand 0.3 mass % or less of Ti; and Al balance including inevitableimpurities, a ratio of a Mn content to a Si content, Mn %/Si %,exceeding 2.5; and a Zn-containing layer provided to an outer surface ofthe tube body, wherein the internal passages are divided by a wall witha thickness of 1.5 mm or less, the heat transfer tube has an extrusionweld part by being formed by extruding works, and selective corrosion atthe extrusion weld part is suppressed. 3: The heat transfer tubeaccording to claim 2, wherein the aluminum alloy further includes: 0.05mass % or less of Cu; less than 0.05 mass % of Mg; and less than 0.03mass % of Cr. 4: The heat transfer tube according to claim 2, wherein3000/mm² or less of intermetallic compound precipitates whose size is1.0 μm or more in a circle equivalent diameter are precipitated in theheat transfer tube after a brazing heat treatment or a Zn diffusingtreatment of the heat transfer tube. 5: The heat transfer tube accordingto claim 2, wherein the aluminum alloy constituting the tube body is analloy subjected to a homogenization treatment in which an ingot of thealuminum alloy after casting is kept at 450-650° C. for 2-24 hours. 6:The heat transfer tube according claim 2, wherein a brazing heattreatment or a Zn diffusing treatment is performed on the heat transfertube at 610° C. or lower. 7: The heat transfer tube according to claim2, wherein a refrigerant flowing an inside of the heat transfer tube isfluorocarbon. 8: The heat transfer tube according to claim 2, wherein2200/mm² or less of intermetallic compound precipitates whose size is1.0 μm or more in a circle equivalent diameter are precipitated in theheat transfer tube after a brazing heat treatment or a Zn diffusingtreatment of the heat transfer tube, the aluminum alloy constituting thetube body is an alloy subjected to a homogenization treatment in whichan ingot of the aluminum alloy after casting is kept at 450-650° C. for2-24 hours, a heating rate from a room temperature to 450° C. is 50-180°C./h; a heating rate from 450° C. to a temperature of the homogenizationtreatment is 10-80° C./h; and a cooling rate from the temperature of thehomogenization treatment to 200° C. is 50-400° C./h, in thehomogenization treatment, a brazing heat treatment or a Zn diffusingtreatment is performed on the heat transfer tube at 610° C. or lower. 9:The heat transfer tube according to claim 8, wherein a corrosionresistance evaluated based on a depth of a maximum corrosion in acorrosion test of SWAAT-20 days is 90 μm or less. 10: The heat transfertube according to claim 9, wherein a corrosion resistance evaluatedbased on a depth of a maximum corrosion in a corrosion test of SWAAT-20days is 50 μm or more.